Additively manufactured fluid pumps and portions thereof

ABSTRACT

In accordance with at least one aspect of this disclosure, embodiments of fluid pumps, pump cases, valve bodies, and volutes are disclosed herein. Embodiments of methods for manufacturing fluid pumps, pump cases, valve bodies, and volutes are also disclosed herein. Embodiments can include additive manufacturing, for example. Certain embodiments can include additively manufacturing a pump case in a tilted orientation, utilizing only coincidental support structure having a unique shape, and with teardrop shaped volute and/or valve body.

FIELD

This disclosure relates to fluid pumps (e.g., augmenter fuel pumps foraircraft).

BACKGROUND

Existing fuel pumps for aircraft are molded and machined. Traditionalfuel pump designs and methods make it difficult, if not impossible, toadditively manufacture certain fuel pumps to be useful and economicalover traditional manufacturing methods, for example.

Conventional methods and designs have generally been consideredsatisfactory for their intended purpose. However, there is still a needin the art for improved fluid pump designs and methods of manufacturing.The present disclosure provides a solution for this need.

SUMMARY

In accordance with at least one aspect of this disclosure, a method formanufacturing a fluid pump can include additively manufacturing a fluidpump case in a tilted orientation without any non-build plate supportstructure in any internal apertures of the fluid pump case except forcoincidental support structure only in one or more coincidentallocations that are already intended to be subjected to post processmilling unrelated to the coincidental support structure. In certainembodiments, the method can include milling the one or more coincidentallocations to a final shape and/or finish, and in the process,eliminating the coincidental support structure.

The one or more coincidental locations can be one or more valve bodiesof the fluid pump case configured to house valve components. The tiltedorientation can include a tilt in at least two axes.

A Cartesian build plate coordinate system can be defined relative to abuild plate. The Cartesian build plate coordinate system can include abuild plate G-axis, a build plate F-axis, and a build plate H-axis. Thebuild plate can have a planar shape define in a build plate G-F plane. ACartesian part coordinate system can be defined relative to the fluidpump case, the Cartesian part coordinate system can include a partG-axis, a part F-axis, and a part H-axis.

In certain embodiments, the tilted orientation can be such that the partH-axis is tilted relative to the build plate H-axis by about 40 degreesto about 45 degrees in the build plate F-H plane, and the part G-axis istilted from the build plate G-axis by about 50 degrees to about 55degrees in the build plate G-F plane.

The tilted orientation can be such that the part H-axis is tiltedrelative to the build plate H-axis by about 43.6 degrees in the buildplate F-H plane, and the part G-axis is tilted from the build plateG-axis by about 52.4 degrees in the build plate G-F plane. The fluidpump case can include a plurality of openings defining a plurality ofparallel axes that are parallel with the part H-axis.

The fluid pump case can include at least one opening defining anon-parallel axis that is not parallel with the part H-axis. In certainembodiments, the at least one non-parallel axis can be orthogonal to theparallel axes. Coincidental support structure can be built within atleast one of the plurality of openings.

In accordance with at least one aspect of this disclosure, anon-transitory computer readable medium, comprising computer executableinstructions configured to cause a computer to execute a method, themethod including operating an additively manufacturing machine to builda fluid pump case layer by layer in a tilted orientation such that nonon-build plate support structure is used in any internal apertures ofthe fluid pump case except for only coincidental support structure inone or more coincidental locations that are already intended to besubjected to post process milling unrelated to the coincidental supportstructure. The method can otherwise be the same or similar to any methoddisclosed herein, e.g., as described above. Any suitable other method(s)and/or portion(s) thereof are contemplated herein.

In accordance with at least one aspect of this disclosure, an additivemanufacturing system can have a non-transitory computer readable mediumas disclosed herein, e.g., as described above. In accordance with atleast one aspect of this disclosure, embodiments can include a means foradditively manufacturing a fluid pump case.

In accordance with at least one aspect of this disclosure, a fuel pumpfor an aircraft can include a fluid pump case formed by any suitablemethod disclosed herein, e.g., as described above. The fluid pump caninclude one or more fluid pump components (e.g., impeller, one or morevalves, etc.) disposed within the fluid pump case.

In accordance with at least one aspect of this disclosure, an additivelymanufactured valve body for a fluid pump case can include an interiorsurface, a plurality of interior annular features integrally formed withand extending radially inwardly from the interior surface and positionedapart in an axial direction relative to each other, and a supportstructure formed integrally with and connecting a lower-in-build annularfeature to a higher-in-build annular feature. In certain embodiments,the support structure can include a filled-in Y-shape.

For example, the support structure can include a stem and a wide portionextending from the stem. The stem of the support structure is integrallyformed with and extends from a lower-in-build portion of thelower-in-build annular feature. The wide portion can extend from thestem and can be integrally formed with and connected to ahigher-in-build portion of the higher-in-build annular feature.

The valve body can include a support structure for each annular feature.Each support structure can extend between each successive pair ofannular features. In certain embodiments, the valve body can beconstructed at an angle between the axial direction and a build platesurface of greater than about 45 degrees.

In accordance with at least one aspect of this disclosure, an additivelymanufactured fluid pump case can include a valve body. For example, thevalve body can be as disclosed herein, e.g., as described above.

In accordance with at least one aspect of this disclosure, a method caninclude additively manufacturing a valve body of fluid pump case asdisclosed herein, e.g., as described above. The method can also includemilling away the support structure while finish-milling the valve body.

In certain embodiments, additively manufacturing can be or include laserpower bed fusion. The method can include removing powder from within thevalve body before milling through openings defined by the supportstructure. The method can include inserting a valve into the valve body.The method can include any other suitable method(s) and/or portionsthereof. Embodiments can include a means for additively manufacturing avalve body as disclosed herein, e.g., as described above.

In accordance with at least one aspect of this disclosure, an additivelymanufactured valve body for a fluid pump case can include an interiorsurface defining a main channel along an axis in an axial direction. Thechannel can have a non-uniform cross-section configured to allow thevalve body to be additively manufactured without support structure.

In certain embodiments, the non-uniform cross-section can have ateardrop shape. For example, the interior surface can include a curvedlower-in-build portion and a ramped higher-in-build portion that forms aV-shape extending from the curved lower-in-build portion. The curvedlower-in-build portion can have a semicircle cross-section. The rampedhigher-in-build portion can include a curved peak. In certainembodiments, the valve body can be additively manufactured such that theaxis forms an angle of about 45 degrees or less with a build platesurface on which the valve body is built.

The interior surface can further define one or more annular groovesextending radially outwardly from the main channel. The one or moreannular grooves include an asymmetric groove profile.

A higher-in-build portion of the one or more annular grooves can includea curved shape in the axial direction, and a lower-in-build portion ofthe one or more annular grooves can include a straight shape in theaxial direction.

In certain embodiments, the one or more annular grooves can be twoannular grooves positioned apart in an axial direction relative to eachother. Any suitable number of annular grooves are contemplated herein.

In accordance with at least one aspect of this disclosure, an additivelymanufactured fluid pump case can include a valve body as disclosedherein, e.g., as described above. In accordance with at least one aspectof this disclosure, a method of manufacturing a fluid pump case caninclude additively manufacturing a valve body as disclosed herein, e.g.,as described above, and machining the main channel to have a differentcross-section to allow the valve body to receive one or more valvecomponents while leaving the one or more annular grooves.

In accordance with at least one aspect of this disclosure, embodimentscan include fluid pump case means for use as a fluid pump housing, thefluid pump case means having valve body means configured to allowadditive manufacturing of the fluid pump case without building supportstructure in the valve body.

In accordance with at least one aspect of this disclosure, a fluid pumpcase can include an interior volute surface defining a volute channel.The interior volute surface can include a first portion having aD-shaped cross-section, a second portion having a teardrop shapedcross-section downstream of the first portion, and a transition portionbetween the first portion and the second portion having a changingcross-section.

The teardrop cross-section can include a curved lower-in-build portionand a ramped higher-in-build portion that forms a V-shape extending fromthe curved lower-in-build portion. The curved lower-in-build portion canhave a semicircle cross-section. The ramped higher-in-build portion canhave a curved peak.

The second portion can be shaped such that it is additively manufacturedwithout support structure. For example, a centerline of the peak alongthe length of the second portion can be coplanar with a vertical builddirection in build such that the teardrop shape is symmetric about avertical plane.

The first portion can have an expanding flow area in a flow directiontoward the second portion. The second portion can have an expanding flowarea or constant flow area in the flow direction.

The volute channel can further include a reducing portion downstream ofthe second portion. The reducing portion can include a teardrop shapecross-section. The reducing portion can be connected to a valve channeldefined by a valve body.

In accordance with at least one aspect of this disclosure, a method caninclude additively manufacturing a fluid pump case to include aninterior volute surface defining a volute channel as disclosed herein,e.g., as described above. Additively manufacturing can include aligninga centerline of the peak along the length of the second portion to becoplanar with a vertical build direction in build such that the teardropshape is symmetric about a vertical plane. In accordance with at leastone aspect of this disclosure, embodiments can include volute means fora fluid pump case.

These and other features of the embodiments of the subject disclosurewill become more readily apparent to those skilled in the art from thefollowing detailed description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art to which the subject disclosureappertains will readily understand how to make and use the devices andmethods of the subject disclosure without undue experimentation,embodiments thereof will be described in detail herein below withreference to certain figures, wherein:

FIG. 1A is a perspective view of an embodiment of a fluid pump case inaccordance with this disclosure;

FIG. 1B is an underside perspective view of the embodiment of FIG. 1A;

FIG. 1C is a perspective view of the embodiment of FIG. 1A shownrelative to a build plate in an embodiment of a tilted build orientationfor additive manufacturing, illustrating a location of a build platecoordinate system and a part coordinate system;

FIG. 1D is a front elevation view of the embodiment of FIG. 1C, showingan embodiment of an angle defined between a first pair of axes of thecoordinate systems;

FIG. 1E is a top down plan view of the embodiment of FIG. 1D, showing anembodiment of an angle between another pair of axes of the coordinatesystems;

FIG. 1F is another perspective view of the embodiment of FIG. 1C;

FIG. 1G is another perspective view of the embodiment of FIG. 1C;

FIG. 1H is another perspective view of the embodiment of FIG. 1C;

FIG. 1I is a cross-sectional perspective view of the embodiment of FIG.1C;

FIG. 1J is a cross-sectional perspective view of a portion of theembodiment of FIG. 1C;

FIG. 1K is a cross-sectional view of the embodiment of FIG. 1C, shownsectioned in a plane approximately parallel to that of FIG. 1I, lookingin an opposite direction;

FIG. 1L is a cross-sectional view of a portion of the embodiment of FIG.1C, sectioned in a plane approximately orthogonal to that of FIG. 1K.

FIG. 1M is a top down plan view of the embodiment of FIG. 1A;

FIG. 1N is an elevation view of the embodiment of FIG. 1A;

FIG. 1O is a bottom up plan view of the embodiment of FIG. 1A;

FIG. 1P illustrates views of an embodiment of a fluid pump assembledutilizing an embodiment of a pump case of FIG. 1A, and indicatinglocations of certain components, inlets, and outlets;

FIG. 2A is an elevation view of an embodiment of a valve body (e.g., fora cooling flow return valve) of a fluid pump case of FIG. 1A inaccordance with this disclosure, e.g., as shown in section in FIG. 1I;

FIG. 2B is a cross-sectional view of the embodiment of FIG. 2A;

FIG. 2C is a schematic view of the embodiment shown in FIG. 2B,illustrating a powder flow path through openings defined by thecoincidental support structure;

FIG. 2D is a cross-sectional perspective view of the embodiment of FIG.2A, showing an embodiment of a build angle between a center axis of thevalve body and a surface of a build plate;

FIG. 2E illustrates an embodiment of a valve body after machining inaccordance with this disclosure, showing the coincidental supportstructure removed;

FIG. 3A is a cross-sectional perspective view of an embodiment ofanother valve body (e.g., for a discharge valve) of the fluid pump caseof FIG. 1A in accordance with this disclosure, e.g., as shown in sectionin FIG. 1L;

FIG. 3B is a cross-sectional view of the embodiment of FIG. 3A, showingan embodiment of a build angle between a center axis of the valve bodyand a surface of a build plate;

FIG. 3C is a cross-sectional view of the embodiment of FIG. 3A,illustrating a powder flow path through the valve body built withoutsupport structure as shown;

FIG. 3D an embodiment of a valve body after machining in accordance withthis disclosure, showing internal shape changed compared to the shape asadditively manufactured;

FIG. 4A is a perspective view of an embodiment of a volute, e.g., of thefluid pump case of FIG. 1A, shown in negative and in isolation;

FIG. 4B shows the embodiment of FIG. 4A within a fluid pump case forcontext;

FIG. 4C is a cross-sectional view of a volute channel defining thevolute of FIG. 4A, showing a teardrop shaped portion thereof;

FIG. 4D is a cross-sectional view of the volute channel of FIG. 4C,shown sectioned in a plane orthogonal to the of FIG. 4C;

FIG. 4E is a cross-sectional view of the volute channel of FIG. 4C,showing a reducing portion of the volute channel connecting to a valvechannel of a valve body;

FIG. 4F is a cross-sectional view of the volute channel of FIG. 4C,shown oriented in a build orientation; and

FIG. 4G is a cross-sectional view of the volute channel of FIG. 4C shownoriented in a built orientation.

DETAILED DESCRIPTION

Reference will now be made to the drawings wherein like referencenumerals identify similar structural features or aspects of the subjectdisclosure. For purposes of explanation and illustration, and notlimitation, an illustrative view of an embodiment of a fluid pump casein accordance with the disclosure is shown in FIGS. 1A and 1 sdesignated generally by reference character 100. Other embodimentsand/or aspects of this disclosure are shown in FIGS. 1B-4F.

FIGS. 1A-1P show various views of an embodiment of a fluid pump case 100to illustrate the 3-dimensional structure of the fluid pump case 100 andan embodiment of a build orientation thereof. FIG. 1A is a topperspective view of an embodiment of a fluid pump case 100 in accordancewith this disclosure. FIG. 1B is an underside perspective view of theembodiment of FIG. 1A. FIG. 1C is a perspective view of the embodimentof FIG. 1A shown relative to a build plate in an embodiment of a tiltedbuild orientation for additive manufacturing, also illustrating alocation of a build plate coordinate system and a part coordinatesystem. FIG. 1D is a front elevation view of the embodiment of FIG. 1C,showing an embodiment of an angle defined between a first pair of axesof the coordinate systems. FIG. 1E is a top down plan view of theembodiment of FIG. 1D, showing an embodiment of an angle between anotherpair of axes of the coordinate systems. FIG. 1F is another perspectiveview of the embodiment of FIG. 1C. FIG. 1G is another front topperspective view of the embodiment of FIG. 1C. FIG. 1H is a rearperspective view of the embodiment of FIG. 1C. FIG. 1I is across-sectional perspective view of the embodiment of FIG. 1C, taken ata diagonal line relative to the build plate. FIG. 1J is across-sectional perspective view of a portion of the embodiment of FIG.1C. FIG. 1K is a cross-sectional view of the embodiment of FIG. 1C,shown sectioned in a plane approximately parallel to that of FIG. 1I,looking in an opposite direction. FIG. 1L is a cross-sectional view of aportion of the embodiment of FIG. 1C, sectioned in a plane approximatelyorthogonal to that of FIG. 1K. FIG. 1M is a top down plan view of theembodiment of FIG. 1A. FIG. 1N is an elevation view of the embodiment ofFIG. 1A. FIG. 1O is a bottom up plan view of the embodiment of FIG. 1A.FIG. 1P illustrates views of an embodiment of a fluid pump assembledutilizing an embodiment of a pump case of FIG. 1A, and indicatinglocations of certain components, inlets, and outlets.

In accordance with at least one aspect of this disclosure, referringgenerally to FIGS. 1A-1P, a method for manufacturing a fluid pump (e.g.,as shown assembled in FIG. 1P) can include additively manufacturing afluid pump case 100 (e.g., as shown in FIGS. 1A and 1B) in a tiltedorientation (e.g., as shown in FIGS. 1C, 1D, 1E, 1F, 1G, 1H, 1I, 1J, 1K,and 1L) such that no non-build plate support structure (i.e., buildplate support structure being support structure that is attached to thebuild plate) is used in any internal apertures of the fluid pump case100 except for only coincidental support structure (e.g., supportstructure 103 a, 103 b, 103 c as shown in FIGS. 1I and 1M) in one ormore coincidental locations 101 a, b, c (e.g., as shown in FIGS. 1A and1M) that are already intended to be subjected to post process millingunrelated to the coincidental support structure. For example, suchlocations can be locations where post process milling (e.g., anysuitable subtractive process) would be required (e.g., for a valve body200) to achieve certain surface finishes and/or tighter tolerances thanavailable with additive manufacturing (e.g., laser powder bed fusion).Various views of an embodiment of the tilted orientation of a suitableembodiment of the pump case 100 is shown in FIGS. 1C-1L.

Certain embodiments may include build plate support structure wheredesired (e.g., for facilitating the tilted orientation). However,certain embodiments may not require certain support structure (e.g.,any, build plate support structure, or other support structure) andsupport structure may not be desired, in which case build plate supportstructure and/or other support structure can be avoided.

In certain embodiments, the method can include milling the one or morecoincidental locations 101 a, b, c to a final shape and/or finish, andin the process, eliminating the coincidental support structure. Anyother suitable post processing in addition to or alternative to millingare contemplated herein.

The one or more coincidental locations 101 a, b, c can be one or morevalve bodies of the fluid pump case 100 configured to house valvecomponents. The valve bodies can be portions of a fluid pump case 100(e.g., integral in the pump case 100 as shown) that are configured tohouse valve components to form a valve, for example.

As illustrated in FIGS. 1C-1E, the tilted orientation can include a tiltin at least two axes. A Cartesian build plate coordinate system 105 canbe defined relative to a build plate 107. The Cartesian build platecoordinate system 105 can include a build plate G-axis, a build plateF-axis, and a build plate H-axis, e.g., as shown. The G, F, and H axesare orthogonal as shown. The H-axis can be a vertical axis, for example.As shown, the build plate 107 can have a planar shape defined in a buildplate G-F plane (the plane defined between the build plate G and Faxes).

A Cartesian part coordinate system 109 can be defined relative to thefluid pump case 100, e.g., as shown. Similar to the build platecoordinate system 105, the Cartesian part coordinate system 109 caninclude a part G-axis, a part F-axis, and a part H-axis (e.g., each axisbeing orthogonal with the others, the H-axis being the vertical axis).As shown, the part H-axis can be aligned with a center axis of a firstopening 111 a (e.g., a pump inlet).

In certain embodiments, as shown in FIG. 1D, the tilted orientation canbe such that the part H-axis is tilted relative to the build plateH-axis by about 40 degrees to about 45 degrees in the build plate F-Hplane. As shown in FIG. 1E, the part G-axis can also be tilted from thebuild plate G-axis by about 50 degrees to about 55 degrees in the buildplate G-F plane. In the embodiment shown, the tilted orientation can besuch that the part H-axis is tilted relative to the build plate H-axisby about 43.6 degrees in the build plate F-H plane, and the part G-axisis tilted from the build plate G-axis by about 52.4 degrees in the buildplate G-F plane.

The fluid pump case 100 can include a plurality of openings 111 b, 111c, 111 d, 111 e defining a plurality of parallel axes (e.g., centeraxes) that are parallel with the part H-axis. The fluid pump case 100can include at least one opening 113 defining a non-parallel axis (e.g.,the center axis thereof) that is not parallel with the part H-axis. Incertain embodiments, the at least one non-parallel axis of the at leastone opening 113 can be orthogonal to the parallel axes of openings 111a, b, c, d, e. Coincidental support structure can be built within atleast one of the plurality of openings, e.g., openings 111 b, 111 d, 111e.

In accordance with at least one aspect of this disclosure, anon-transitory computer readable medium can include computer executableinstructions configured to cause a computer to execute a method. Themethod can include operating an additively manufacturing machine tobuild a fluid pump case layer by layer in a tilted orientation such thatno non-build plate support structure is used in any internal aperturesof the fluid pump case except for only coincidental support structure inone or more coincidental locations that are already intended to besubjected to post process milling unrelated to the coincidental supportstructure. The method can be the same or similar to any method disclosedherein, e.g., as described above. Any suitable other method(s) and/orportion(s) thereof are contemplated herein.

In accordance with at least one aspect of this disclosure, an additivemanufacturing system can have a non-transitory computer readable mediumas disclosed herein, e.g., as described above. In accordance with atleast one aspect of this disclosure, embodiments can include a means foradditively manufacturing a fluid pump case. Embodiments can includefluid pump case means, e.g., as shown in the figures and/or describedabove.

In accordance with at least one aspect of this disclosure, a fuel pump99 (e.g., as shown in FIG. 1P) for an aircraft can include a fluid pumpcase, e.g., fluid pump case 100 formed by any suitable method disclosedherein, e.g., as described above. The fluid pump 99 can include one ormore fluid pump components known to those having ordinary skill in theart disposed within the fluid pump case 100, e.g., an ejector inlet 150,1 shut off solenoid 152, a BSD outlet 154, a cooling flow return 156, anaugmentor discharge 158, a main flow inlet 160, an ejector outlet 164, aselector valve 166, a pressure temperature sensor 168, an impeller (notshown), and any other suitable pump components appreciated by thosehaving ordinary skill in the art (e.g., for an augmentor fuel pump foraircraft).

To aid in defining the shown embodiment of a build orientation, belowprovided in Table 1 is an embodiment of positions of noted points shownin FIG. 1C relative to the build plate coordinate system. Any othersuitable positions that achieve similar results are contemplated herein.The positions are shown in inches.

TABLE 1 CO-ORDINATES POINTS F-BASIC G-BASIC H-BASIC A −6.0150 −2.964711.6542 B −8.1721 −1.3031 10.1004 C −2.4793 .5027 4.1281 D .0000 .0000.0000

An embodiment of diameters of openings in the fluid pump case 100 isshown below in Table 2. Any other suitable dimensions are contemplatedherein. The dimensions below are reflected in inches.

TABLE 2 POINTS DIAMETER 1 ∅ 1.678 ± .005 2 ∅ 1.730 3 ∅ .435 4 ∅ 1.310 5∅ 1.350 6 ∅ .500 7 ∅ .311 8 NOT APPLICABLE

Embodiments can include a certain shape (e.g., of one or more channels)and a tilted orientation thereof to allow building with additivemanufacturing efficiently. Embodiments can include an orientation ofbuild to avoid extra support structure that would not be machined awaywith already existing machining. For example, each valve body in atraditional fluid pump case can be milled after traditional casting toprovide a final shape and a final finish. Such post processing can berequired for additive manufacturing as well. Thus, each valve body canhave support structure added therein without adding additional steps ofmilling. Accordingly, the tilted orientation can be selected such thatsupport structure internal to the device is only utilized where millingis necessary.

Embodiment of additive manufacturing include laser powder bed fusion.Any other suitable process is contemplated herein. In certainembodiments, supports are not permissible on any internal surfaces ofthe part that are not already going to be machined away. Certainapplications (e.g., for aircraft fuel pumps) may require the pump caseto be clean, burr free, and powder free, and some surfaces may require amachined finish while others may not.

In certain embodiments, the recoater direction (e.g., the direction apowder recoater of a powder bed fusion machine moves to recoat) can bein the positive F-axis direction of build plate coordinate system (e.g.,the direction arrow is pointing in the FIG. 1C). The build direction canbe the positive H-axis direction of build plate coordinate system (e.g.,vertical).

Embodiments can allow additive manufacturing of an augmentor fuel pumpcase which was initially designed and optimized for a castingmanufacturing process. Castings generally have high startup cost andlong lead times. Additive manufacturing (AM) can be an enablingtechnology for this part to save costs in the supply chain and maintainor improve part performance when properly redesigned for bothperformance, cost, and manufacturability.

The AM build configuration as disclosed herein can be an intermediatestep, as there can be post AM processes that are used to create thefinal part (e.g., machining the valve bodies to finish while removingany support structure). The orientation, support structure, andmodifications of embodiments of an additively manufactured fluid pumpcase are unique compared to a traditional cast pump case.

Through utilizing a tilted orientation as disclosed above, and designfeatures that avoid the use of internal support structures in hard toreach or traditionally unfinished locations, embodiments of a method canenable improved manufacturing of an augmenter fuel pump through additivemanufacturing For example, embodiments of the fluid pump case can have aset of unique design changes, support structures in only coincidentallocations, and an orientation definition to allow the pump case for theaugmentor fuel pump to be additively manufactured without negativelyimpacting performance. Embodiments utilizing such a tilted orientation,design, and with only coincidental support structure and also enablereduced AM post processing cost, eliminate support removal activityrequired that is not incorporated in existing machine operations, allowfor easy powder removal (e.g., no wells or small features), provide thesame or less weight as traditional casted parts, and provide equal orbetter performance compared to traditional casted parts. Thus, pumpcases can be additively manufactured while reducing cost and at leastmaintaining performance.

In accordance with at least one aspect of this disclosure, referringadditionally to FIGS. 2A-2E, an additively manufactured valve body 200for a fluid pump case (e.g., pump case 100) can include an interiorsurface 201 and a plurality of interior annular features 203 a, 203 b,203 c, 203 d, 203 e integrally formed with and extending radiallyinwardly from the interior surface 201. The interior surface 201 canform a substantially cylindrical shape, for example. The one or moreannular features 203 a, b, c, d, e can be positioned apart in an axialdirection (e.g., along centerline axis 205) relative to each other,e.g., for forming a plurality of lands.

The valve body 200 can include a support structure 207 a, b, c, d (e.g.,a plurality thereof as shown) formed integrally with and connecting alower-in-build annular feature (e.g., annular feature 203 b) to ahigher-in-build annular feature (e.g., annular feature 203 c). Forexample, as shown in FIG. 2D, the relative higher and lower positionscan be seen relative to the build plate 107. The support structure 207a, b, c, d can be any of the support structure 103 a, b, c, d asdescribed above (e.g., support structure 103 a in FIG. 1M is the same assupport structure 207 d shown in FIG. 2A).

In certain embodiments, as best shown in FIG. 2A, the support structure207 can include a filled-in Y-shape. Such a shape can allow for powderremoval and cleaning, while providing adequate support and limitingwaste material when removed, for example. The support structure 207 a,b, c, d can form openings 215 a, 215 b, for example, allowing powderremoval. For example, the support structure 207 a, b, c, d can include astem 209 and a wide portion 211 extending from the stem 209. The stem209 can be thinner than the wide portion 211. The wide portion 211 caninclude a quasi-circular shape, or any other suitable shape, and can besolid (e.g., as shown) or have any suitable discontinuities.

The stem 209 of the support structure 207 a, b, c, d can be integrallyformed with and extend from a lower-in-build portion, e.g., portion 213a of the lower-in-build annular feature (for example, feature 203 c).The wide portion 211 can extend from the stem 209 and can be integrallyformed with and connected to a higher-in-build portion (e.g., portion213 b) of the higher-in-build annular feature (e.g., feature 203 d).

Any suitable number of support structures are contemplated herein (e.g.,to provide support during build for any would-be overhanging features).The valve body 200 can include a support structure 207 a, b, c, dconnecting to each annular feature 203 a, b, c, d, e (e.g., oneconnecting each pair such that the total is one less than annularfeatures). As shown, each support structure 207 a, b, c, d can extendbetween each successive pair of annular features 203 a, b, c, d, e. Inthis regard, the support structure 207 a, b, c, d can be milled away inthe process of milling the annular features 203 a, b, c, d, e to theirfinal shape and/or finish since all support structure can connect to theinner diameter of the annular features. An embodiment of a milled valvebody 200 is shown in FIG. 2E.

In certain embodiments, as shown in FIG. 2D, the valve body 200 can beconstructed at an angle between the axial direction 205 and a surface ofthe build plate 107 of greater than about 45 degrees. Any other suitableangle is contemplated herein (e.g., to allow suitable additivemanufacturing of the valve body 200 (e.g., with the case 100 asdescribed above). For example, the build angle can be such that nounsupported surface is less than about 20 degrees from horizontal.

The valve body 200 can be additively manufacture as part of the case 100as described above. Any other suitable application (e.g., in isolationof the case) is contemplated herein. In certain embodiments, thedisclosed embodiments of support structure can be applied to any channelshaped body build at a suitable angle using additive manufacturing.

In accordance with at least one aspect of this disclosure, an additivelymanufactured fluid pump case (e.g., case 100) can include a valve body.The valve body can be any suitable valve body as disclosed herein, e.g.,valve body 200 as described above. In accordance with at least oneaspect of this disclosure, a method can include additively manufacturinga valve body (e.g., valve body 200) of fluid pump case (e.g., fluid pumpcase 100). The method can also include milling away the supportstructure 207 a, b, c, d while finish-milling the valve body 200, forexample.

In certain embodiments, and as disclosed above with respect to FIGS.1A-1P, additively manufacturing can be or include laser power bedfusion. Any other suitable process is contemplated herein (e.g., fuseddeposition, etc.). The method can include removing powder from withinthe valve body 200 before milling through openings 215 a, 215 b definedby the support structure 207 a, b, c, d. The method can includeinserting a valve (not specifically shown) into the valve body 200(e.g., after being milled). For example, the valve can be a selectorvalve having a circumferentially defined flow path based on its axialand/or rotational position within the valve body 200.

This method can include any other suitable method(s) and/or portionsthereof. Embodiments can include a means for additively manufacturing avalve body (e.g., valve body 200).

In certain additive manufacturing processes, there is a need for apowder flow path to remove powder from internal channels of parts.Embodiments disclosed herein provide support structure than can includea trunk extending upward and forward from a lower land, and a branchportion that contacts next land up from lower land. Certain fuel pumpsare complex in shape and can benefit from embodiments of supportstructure disclosed in FIG. 2A-2E to provide additive manufacturingsolutions that can save in powder removal costs by reducing powderremoval time. Accordingly, embodiments of the support structure of FIGS.2A-2E can provide a reduced additive manufacturing post processing cost,easy powder removal, increased volume air/powder/medium, reducedsintered feed stock material, no modification of machining process, andthe same or better valve performance. Valve body geometry andorientation can be a performance consideration of the part, and thepositioning thereof can be a function of the mating valve assembly'sstraight line action and associated parts.

When valve bodies are at low build angles (e.g., caused by an overallorientation that is greater than about 45 degrees), they can havefeatures that present build risk. Traditional redesigning solutions suchas removing an overhanging surface and creating small powder removalholes drive up powder removal cost or are not feasible. By applyingembodiments of the support structure disclosed (e.g., a “Y” supportgeometry) to connect surfaces that are to be machined, valve bodies thatare to be built via additive manufacturing and oriented at about 45degrees from horizontal can be supported while allowing ease of powderremoval and minimizing sintered material that will become machinedstock.

Fuel pumps can use valves housed in such valve bodies as described aboveto regulate flow to primary and secondary systems of the pump. Valvebodies can have internal tubes that interface in the grooves (betweenannular features) of the body. The mating valve can interface with thelands of the valve body. Traditionally, these surfaces in the valve bodyhave only be subtractively processed (e.g., machined/milled) to meetinterface requirements regardless of manufacturing method. Any othersuitable additive or subtractive post processing finishing method iscontemplated herein.

In accordance with at least one aspect of this disclosure, referringadditionally to FIGS. 3A-3D, an additively manufactured valve body 300for a fluid pump case (e.g., pump case 100) can include an interiorsurface 301 defining a main channel 303 along an axis 305 (e.g., asshown in FIG. 3B) in an axial direction. The channel 303 can have anon-uniform cross-section configured to allow the valve body 301 to beadditively manufactured without support structure, e.g., as shown inFIG. 3A.

In certain embodiments, as can be seen in FIG. 1C, for example, thenon-uniform cross-section can have a teardrop shape. For example, theinterior surface 301 can include a curved lower-in-build portion 301 aand a ramped higher-in-build portion 301 b that forms a V-shapeextending from the curved lower-in-build portion 301 a. As shown, thecurved lower-in-build portion 301 a can have a semicircularcross-section. The ramped higher-in-build portion 301 b can include acurved peak 307 where the ramped surfaces meet. The ramped surfaces canform any suitable angle extending from the lower-in-build portion 301 a(e.g., about 30 to about 45 degrees). In certain embodiments, the valvebody 300 can be additively manufactured such that the axis 305 forms anangle of about 45 degrees or less with a surface of the build plate 107on which the valve body 300 is built.

The interior surface 301 can further define one or more annular grooves309 extending radially outwardly from the main channel 303. The one ormore annular grooves 309 can include an asymmetric groove profile. Forexample, a higher-in-build portion 309 a of the one or more annulargrooves 309 can include a curved shape in the axial direction (e.g.,U-shaped cross-section as shown in FIG. 3A), and a lower-in-buildportion 309 b of the one or more annular grooves 309 can include astraight shape (e.g., rectilinear shaped cross-section as shown in FIG.3A) in the axial direction.

In certain embodiments, the one or more annular grooves 309 can be twoannular grooves 309 positioned apart in an axial direction relative toeach other, e.g., as shown. Any suitable number of annular grooves 309are contemplated herein.

The internal shape of the valve body 300 can enable additivemanufacturing of the valve body 300, e.g., as part of the fluid pumpcase 100 in the orientation disclosed in relation to FIGS. 1A-1P withoututilizing support structure. For example, the valve body 300 can bepositioned less than about 45 degrees in the tilted build orientation asdescribed above. The shape of the interior surface 301 can be milledafter additive manufacturing into a uniform cross-sectional shape (e.g.,a cylindrical shape) as shown in FIG. 3D (e.g., with milled lands for avalve assembly (e.g., similar as disclosed above in FIGS. 2A-2E). Whilethe valve body 300 is shown integrated with the fluid pump case 100, anysuitable application (e.g., in isolation of the pump case 100) iscontemplated herein.

In accordance with at least one aspect of this disclosure, an additivelymanufactured fluid pump case (e.g., case 100) can include a valve body300 as disclosed herein, e.g., as described above. In accordance with atleast one aspect of this disclosure, a method of manufacturing a fluidpump case (e.g., case 100) can include additively manufacturing a valvebody 300 as disclosed herein, e.g., as described above, and machiningthe main channel 303 to have a different cross-section to allow thevalve body 300 to receive one or more valve components while leaving theone or more annular grooves 309.

In accordance with at least one aspect of this disclosure, embodimentscan include fluid pump case means for use as a fluid pump housing, thefluid pump case means having valve body means configured to allowadditive manufacturing of the fluid pump case without building supportstructure in the valve body.

Embodiments can have tops of grooves with a round cross-section to allowa smooth build without low overhang while the bottoms of the grooves canhave a square cross-section. The total volume of the grooves can beabout the same as a traditional design to allow the performance to bethe same or similar to traditional embodiments. Embodiments of the valvebody 300 can have a teardrop shape that allows open area for powerremoval, for example. As presented above, embodiments can allow forbuilding certain valve bodies (e.g., valve body 300 of a fluid pump case100) at build angles of less than about 45 degrees relative to the axisof channel 303.

Embodiments can include a teardrop self-supporting profile that alsoprovide ample powder removal flow area (e.g., the whole of teardropshaped channel 303 after additive manufacturing and before milling). Byapplying a unique teardrop profile to the valve body 300, coupled withan asymmetric groove using a semi-circular cross section swept into arectangular cross section, the low angle-in-build valve body can beself-supporting without restricting powder flow.

In accordance with at least one aspect of this disclosure, referringadditionally to FIGS. 4A-4G, a fluid pump case, e.g., fluid pump case100, can include an interior volute surface 401 defining a volutechannel 400. The interior volute surface 401 can include a first portion401 a having a D-shaped cross-section and a second portion 401 b havinga teardrop shaped cross-section downstream of the first portion 401 a.The interior volute surface can include a transition portion 401 cbetween the first portion 401 a and the second portion 401 b having achanging cross-section (e.g., that morphs from a D-shaped cross-sectionto a teardrop shaped cross-section while curving as shown). Thetransition portion 401 c can be defined between lines 409 a and 409 b,e.g., as shown in FIGS. 4A and 4D.

The teardrop cross-section can include a curved lower-in-build portion403 a and a ramped higher-in-build portion 403 b that forms a V-shapeextending from the curved lower-in-build portion 403 a. In certainembodiments, the teardrop cross-sectional shape can be the same orsimilar to that disclosed above with respect to the valve body 300 ofFIG. 3A. For example, the curved lower-in-build portion 401 a can have asemicircle cross-section, e.g., as shown. The ramped higher-in-buildportion can have a curved peak 405. In certain embodiments, the teardropcross-section can be aligned with the teardrop shape of the valve body300.

The second portion 401 b can be shaped such that it is additivelymanufactured without support structure, e.g., as shown. For example, acenterline of the peak 405 (e.g., as shown in FIGS. 4A and 4C) along thelength of the second portion 401 b can be coplanar with a vertical builddirection (and a centerline axis of the volute channel 400) in buildsuch that the teardrop shape is symmetric about a vertical plane (e.g.,on which the vertical build axis lays), e.g., as illustrated in FIG. 4G.Any suitable variation or asymmetry that still allows building withoutsupport structure is contemplated herein. As shown, the teardrop shapeis rotated about 45 (e.g., about 43.6) degrees relative to a pumpcenterline axis.

As shown, the first portion 401 a can have an expanding flow area in aflow direction toward the second portion 401 b. The second portion 401 bcan have an expanding flow area or constant flow area in the flowdirection, for example. In certain embodiments, the volute channel 400can consistently expand from the first portion 401 a through the secondportion 401 b.

The volute channel 400 can further include a reducing portion 407downstream of the second portion 401 b. The reducing portion 407 caninclude a teardrop shape cross-section also, or any other suitable shapeto allow building without support structure. The reducing portion 407can be connected to a valve channel (e.g., channel 303) defined by avalve body (e.g., valve body 300). Embodiments can be utilized with theabove disclosed fluid pump case 100 or any other suitable application(e.g., in isolation from fluid pump 100).

Embodiments can be oriented such that the peak 405 of the teardrop ispositioned relative to the build area such that neither ramped wallforming the ramped higher-in-build portion will be less than about 20degrees from horizontal, for example. The peak 405 of the teardrop shapecan be in any suitable orientation as long as the build orientation ofthe volute channel 400 is changed to have the ramped portion where anoverhang would be. The shown position of the teardrop shape is asuitable position for the tilted orientation described above withrespect to FIGS. 1A-1P. The above embodiments of valve bodies 200, 300are also shown shaped and oriented (with or without build structure asdescribed above) to allow for building in the tilted orientationdescribed above with respect to FIGS. 1A-1P.

Unlike certain embodiments of the valve bodies 200, 300 disclosed above,the interior surface 401 need not be milled to a final shape and canmaintain the teardrop shape in the final device. While the teardropstructure allows building without support structure, it also maintainsstrength under pressure. Such a shape is acceptable in use withoutcompromising function. Embodiments can include transitions before andafter the teardrop that are smooth to aid in powder removal, forexample, as opposed to traditional embodiments that have sharp anglesthat are machined away. This also reduces post processing required sincethe reducing portion of the volute channel is already formed to thedesired shape.

In accordance with at least one aspect of this disclosure, a method caninclude additively manufacturing a fluid pump case to include aninterior volute surface 401 defining a volute channel 400 as disclosedherein, e.g., as described above. Additively manufacturing can includealigning a centerline of the peak 405 along the length of the secondportion 401 b to be coplanar with a vertical build direction in buildsuch that the teardrop shape is symmetric about a vertical plane. Inaccordance with at least one aspect of this disclosure, embodiments caninclude volute means for a fluid pump case.

Fuel pumps use volutes designed for the casting manufacturing processwith input from CFD models, for example. The part can be surface finishcritical, with limited to no line of sight to feature geometry. Volutedesign can be critical to the function of a pump as it collects andslows the flow while maintaining minimal pressure from the inletimpeller assembly. To maintain part performance, traditional volutegeometry cannot be used if the pump case is to be additively manufacturewhile also maintaining a cost practicality.

The fuel pump volute is composed of a fluid passage that receives fuelfrom a series passages connected to the impeller volume, as appreciatedby those having ordinary skill in the art and as shown in the abovedescribed figures (e.g., all connected to the first portion 401 a and/ortransition portion 401 c). In pump embodiments, e.g., as shown in FIG.1P, the volute transmits the fluid from the inlet impeller assembly tothe valve system (e.g., associated with valve body 300) that connects toa fluid (e.g., fuel) discharge while maintaining minimal loss ofpressure.

The volute is highly sensitive to pressure drop, which is directlyaffected by cross-sectional area, cross-sectional shape, volume, path,volume expansion rate, and surface roughness. Typical devices caninclude a semi rectangular “D” cross-section that transitions into acircle shape, however, this cannot be properly additively manufactured(e.g., at least in the tilted orientation disclosed above with respectto FIGS. 1A-1P) at least due to the fact that support structure would berequired and would be difficult if not impossible to remove.

Embodiments include a teardrop non-uniform pump volute that is aself-supporting volute via a unique volute profile and shape.Embodiments can include a volute profile can transition from a CFDdriven “D” shaped cross section to a teardrop shape based on partorientation. This customized feature shape driven by the partorientation can allow the fuel pump to be additively manufactured withno need for support structure, and therefore no support removal costs.Embodiments also minimize high surface roughness areas having theteardrop oriented with the build direction. Embodiments also provide asmoother volute to valve transition and powder removal and flow benefit.

Embodiments provide reduced additive manufacturing post processingcosts, no support structure in the volute, easy powder removal (e.g., nowells or small features), weight neutral lighter pump cases, a moreefficient structural transition from the D shaped cross-section to theteardrop shape compared to traditional D-to-round transitions, equal orbetter performance, no integral supports or additional materialobstructing flow paths, approximately equivalent volute cross-sectionalarea (e.g., within 3%), approximately equivalent volute volumeequivalent (e.g., within 3%), minimal area of surface roughness (e.g.,less than 400, arched downskin), and a smoother volute to valveflowpath.

While certain figures may include embodiments of dimensions and relativedimensions, such dimensions and relative dimensions are not limiting.Any suitable dimensions or relative dimensions to allow additivemanufacturing and/or for any suitable application are contemplatedherein. Any suitable size or scale of the embodiments shown iscontemplated herein.

Those having ordinary skill in the art understand that any numericalvalues disclosed herein can be exact values or can be values within arange. Further, any terms of approximation (e.g., “about”,“approximately”, “around”) used in this disclosure can mean the statedvalue within a range. For example, in certain embodiments, the range canbe within (plus or minus) 20%, or within 10%, or within 5%, or within2%, or within any other suitable percentage or number as appreciated bythose having ordinary skill in the art (e.g., for known tolerance limitsor error ranges).

The articles “a”, “an”, and “the” as used herein and in the appendedclaims are used herein to refer to one or to more than one (i.e., to atleast one) of the grammatical object of the article unless the contextclearly indicates otherwise. By way of example, “an element” means oneelement or more than one element.

The phrase “and/or,” as used herein in the specification and in theclaims, should be understood to mean “either or both” of the elements soconjoined, i.e., elements that are conjunctively present in some casesand disjunctively present in other cases. Multiple elements listed with“and/or” should be construed in the same fashion, i.e., “one or more” ofthe elements so conjoined. Other elements may optionally be presentother than the elements specifically identified by the “and/or” clause,whether related or unrelated to those elements specifically identified.Thus, as a non-limiting example, a reference to “A and/or B”, when usedin conjunction with open-ended language such as “comprising” can refer,in one embodiment, to A only (optionally including elements other thanB); in another embodiment, to B only (optionally including elementsother than A); in yet another embodiment, to both A and B (optionallyincluding other elements); etc.

As used herein in the specification and in the claims, “or” should beunderstood to have the same meaning as “and/or” as defined above. Forexample, when separating items in a list, “or” or “and/or” shall beinterpreted as being inclusive, i.e., the inclusion of at least one, butalso including more than one, of a number or list of elements, and,optionally, additional unlisted items. Only terms clearly indicated tothe contrary, such as “only one of” or “exactly one of,” or, when usedin the claims, “consisting of,” will refer to the inclusion of exactlyone element of a number or list of elements. In general, the term “or”as used herein shall only be interpreted as indicating exclusivealternatives (i.e., “one or the other but not both”) when preceded byterms of exclusivity, such as “either,” “one of,” “only one of,” or“exactly one of.”

Any suitable combination(s) of any disclosed embodiments and/or anysuitable portion(s) thereof are contemplated herein as appreciated bythose having ordinary skill in the art in view of this disclosure.

The embodiments of the present disclosure, as described above and shownin the drawings, provide for improvement in the art to which theypertain. While the subject disclosure includes reference to certainembodiments, those skilled in the art will readily appreciate thatchanges and/or modifications may be made thereto without departing fromthe spirit and scope of the subject disclosure.

1. An additively manufactured valve body, comprising: an interiorsurface; a plurality of interior annular features integrally formed withand extending radially inwardly from the interior surface and positionedapart in an axial direction relative to each other; and a supportstructure formed integrally with and connecting a lower-in-build annularfeature of the plurality of interior annular features to ahigher-in-build annular feature of the plurality of interior annularfeatures, wherein the support structure includes a filled-in Y-shape. 2.(canceled)
 3. The valve body of claim 1, wherein the support structureincludes a stem and a wide portion extending from the stem.
 4. The valvebody of claim 3, wherein the stem of the support structure is integrallyformed with and extends from a lower-in-build portion of thelower-in-build annular feature, wherein the wide portion extends fromthe stem and is integrally formed with and connected to ahigher-in-build portion of the higher-in-build annular feature.
 5. Thevalve body of claim 1, further comprising a plurality of the supportstructure, one for each annular feature.
 6. The valve body of claim 5,wherein each support structure extends between each successive pair ofannular features.
 7. The valve body of claim 6, wherein the valve bodyis constructed such that there is an angle between the axial directionand a build plate surface on which the valve body is constructed,wherein the angle is greater than about 45 degrees.
 8. An additivelymanufactured fluid pump case, comprising: the valve body of claim
 1. 9.(canceled)
 10. The fluid pump case of claim 8, wherein the supportstructure includes a stem and a wide portion extending from the stem.11. The fluid pump case of claim 10, wherein the stem of the supportstructure is integrally formed with and extends from a lower-in-buildportion of the lower-in-build annular feature, wherein the wide portionextends from the stem and is integrally formed with and connected to ahigher-in-build portion of the higher-in-build annular feature.
 12. Thefluid pump case of claim 8, further comprising a support structure foreach annular feature.
 13. The fluid pump case of claim 12, wherein eachsupport structure extends between each successive pair of annularfeatures.
 14. The fluid pump case of claim 13, wherein the valve body isconstructed at an angle between the axial direction and a build platesurface of greater than about 45 degrees.
 15. A method, comprising:additively manufacturing a valve body, the valve body comprising: aninterior surface; a plurality of interior annular features integrallyformed with and extending radially inwardly from the interior surfaceand positioned apart in an axial direction relative to each other; and asupport structure formed integrally with and connecting a lower-in-buildannular feature of the plurality of interior annular features to ahigher-in-build annular feature of the plurality of interior annularfeatures; and milling away the support structure while finish-millingthe valve body.
 16. The method of claim 15, wherein additivelymanufacturing includes laser power bed fusion.
 17. The method of claim16, further comprising removing powder from within the valve body beforemilling through openings defined by the support structure.
 18. Themethod of claim 15, further comprising inserting a valve into the valvebody.
 19. An additively manufactured valve body, comprising: an interiorsurface; a plurality of interior annular features integrally formed withand extending radially inwardly from the interior surface and positionedapart in an axial direction relative to each other; and a supportstructure formed integrally with and connecting a lower-in-build annularfeature of the plurality of interior annular features to ahigher-in-build annular feature of the plurality of interior annularfeatures, wherein the valve body includes a plurality of the supportstructure, one for each annular feature, wherein each support structureextends between each successive pair of annular features, wherein thevalve body is constructed such that there is an angle between the axialdirection and a build plate surface on which the valve body isconstructed, wherein the angle is greater than about 45 degrees.
 20. Amethod, comprising: additively manufacturing the valve body of claim 15;and removing the support structure after additively manufacturing thevalve body.